help me with gear repair question

[dpotter58]

I downloaded the threads from the repair section dealing with the gear repairs. Mine skips in first.
I have dissasembled to the point of pulling the shift fork shaft out and removing the 5th gear and the nest step says
"Next, you can pull the shift fork shaft the rest of the way out, allowing the other 2 shift forks to slide down into the engine
I pulled it out but I'm only seeing two forks. (the same two I see in the tech tip)They are labled 21,22 and 23 or fork shift 1, 2, and 3 on the yamaha parts diagram.
Here is a photo of my transmission.

Where are the three forks supposed to be in relation to the gears?
It seems like when I try to pull the countershaft off the forks are in the way and I can't get the assembly out.
I'm almost certain I am in 4th gear; could it be that I shifted somehow and I'm not in 4th anymore?

[TopCatGr58]

Hey Potter,

You've got the 3 shift forks, the middle one is pointing down/upward into the engine!

IIRC, I had to lift up the shift forks, and twist/turn them sideways so that the gears could move past them! You might want to take a marker and put a mark on one of the shift forks so that you can remember which way it goes when putting things back in!
HTH?
T.C.

[XSPastor]

You need to pull out the shift fork shaft. There is a circlip on the left side of the engine on the end of the shaft. Remove it and, if you are in fourth gear, it will slide out easily allowing you to remove the countershaft. The oil pump idler gear is on the other end of the shift fork shaft.

[dpotter58]

Originally posted by XSPastor
You need to pull out the shift fork shaft. There is a circlip on the left side of the engine on the end of the shaft. Remove it and, if you are in fourth gear, it will slide out easily allowing you to remove the countershaft. The oil pump idler gear is on the other end of the shift fork shaft.

Yep, I pulled the shaft but I'm still fighting the forks...

[XSPastor]

I just played with them until they fell out. I'm working on getting them back in now and it's proving much harder!

[dpotter58]

Originally posted by XSPastor
I just played with them until they fell out. I'm working on getting them back in now and it's proving much harder!

I got them out and dangit all I had to go buy a dremel I ended up rolling the shift cam a notch or was it two? and I was able to get them out of the way....Hope it all goes back together...

[XSPastor]

Hey good luck. I just got mine back together after doing the 2nd gear fix. Shifts great now. I replaced the gears with new from Yamaha - didn't bother with the Dremel. Just take your time - you'll get it. Those shift forks are a bugger - especially if the bike is not turned over. It's hard to hold the shaft and the forks and get it all in working against gravity. Took me about an hour to get the shaft and all three forks back in. I can certainly see why guys turn the bike over to do this fix.

[dpotter58]

Glad to hear it. How much did the gears run you

[XSPastor]

2nd gear was 76.64, 5th gear was 90.97. Got them from www.yamahaaccy.com. I also replaced 1st and 4th with a donor transmission I picked up off Ebay for 50 bucks.

[XSPastor]

The link in the previous email wont work unless you take the period off the end.

www.yamahaaccy.com